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I wanted to take the time to document my changing of an oil sender unit on a 2003 9-5 linear LPT 2.3. To start off you need the engine stone cold. Before you jack it up disconnect the negative terminal of the battery and lay if well off to the side (starter must be removed). Then remove the intake cover from the engine. Using a 13MM wrench access the positive nut on the starter solenoid by approaching from the passenger side with you arm behind the intake manifold and under. Pull the heavy battery cable off the starter solenoid. Then use a 10MM deep well socket on a ¼ inch drive to loosen the solenoid yellow start actuator wire. Remove the nut and pull off the wire. Cut the pull tie that goes around the solenoid and remove.
Jack the car up high and put on jack stands. From underneath the car use an 18mm socket on a short ratchet to a remove the long bolt on the top of the starter. There is a limit one hand and arm that Saab allows to pass past the catalytic converter from underneath the car. Then use a 16mm wrench to remove the nut on the lower stud that holds on the starter. Remove the starter and believe it or not that little Mitsubishi starter will pass that small hole by the catalytic converter. They you have a full view of the oil sender. It is a trick to disconnect the Saab type of electrical connectors that pull together with only one hand. I used a very small flat screwdriver to insert in the slot under the red push tab to undo this connection. Then I used a ½ drive 12 point 24mm socket. The 12 point allows the wire to reside in the not utilized point since the electrical connector is too big to thread through. Have your new sender and rag ready you will lose oil when you remove it and need to screw in the new one immediately. Screw the new sender in and make sure the threads are not crossed. Use the 12 point 24mm socket to tighten and carefully let the wire pass by and not bind in the socket. Then the fun part. Single handed (remember limit one arm pass the converter) making the electrical connection. Then install the starter with the 16mm nut first careful not to have any wires between the starter and bell housing particularly the oil sender wire. I had a helper hold up the tail of the starter from the topside to allow me to get the proper angle to start the 18mm bolt in the top of the starter and not cross thread it. Secure both bolts. Put back the 13mm nut for the battery cable, the 10mm nut for the solenoid wire and install a new pull tie around the wiring. This was fun also. Reinstall the intake cover and test car for light function and leaks. All of this for an oil sender that will fail again. I hope this helps.
posted by 69.69.22...
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